Flexible fluid-filled chamber with tensile member

ABSTRACT

A method of making an article of footwear. The method may include forming a chamber for receiving a pressurized fluid, including a first chamber barrier layer, a second chamber barrier layer, and a tensile member extending between the first chamber barrier layer and the second chamber barrier layer. The tensile member may include a first tensile member layer, a second tensile member layer, and a plurality of tethers connecting the first tensile member layer to the second tensile member layer. The method may also include extending a portion of the second chamber barrier layer toward the first tensile member layer between a first section of the second tensile member layer and a second section of the second tensile member layer, and joining the portion of the second chamber barrier layer to the first tensile member layer between the first section and the second section of the second tensile member layer.

FIELD

The present invention relates generally to fluid-filled chambers for usein the sole structure of an article of footwear.

BACKGROUND

Conventional articles of athletic footwear include two primary elements,an upper and a sole structure. The upper provides a covering for thefoot that comfortably receives and securely positions the foot withrespect to the sole structure. The sole structure may includefluid-filled chambers to provide cushioning and stability. The solestructure is secured to a lower portion of the upper and is generallypositioned between the foot and the ground. In addition to attenuatingground reaction forces (that is, providing cushioning and stabilizingthe foot during vertical and horizontal loading) during walking,running, and other ambulatory activities, the sole structure mayinfluence foot motions (for example, by resisting pronation), impartstability, and provide traction. Accordingly, the upper and the solestructure operate cooperatively to provide a comfortable structure thatis suited for a wide variety of athletic activities.

BRIEF SUMMARY

In one aspect, the present disclosure is directed to an article offootwear may have an upper and a sole structure secured to the upper.The sole structure may include a chamber for receiving a pressurizedfluid, the chamber having a first chamber barrier layer and a secondchamber barrier layer bonded to the first chamber barrier layer aboutperipheral portions of the first chamber barrier layer and the secondchamber barrier layer to define an interior void between the firstchamber barrier layer and the second chamber barrier layer. In addition,the chamber may include a tensile member extending between the firstchamber barrier layer and the second chamber barrier layer, the tensilemember including a first tensile member layer bonded to the firstchamber barrier layer, a second tensile member layer bonded to thesecond chamber barrier layer, and a plurality of tethers connecting thefirst tensile member layer to the second tensile member layer. Thesecond tensile member layer may include a first section and a secondsection separate from the first section. A portion of the second chamberbarrier layer may extend toward the first tensile member layer betweenthe first section and the second section of the second tensile memberlayer, the portion of the second chamber barrier layer that extendstoward the first tensile member layer being joined to the first tensilemember layer.

In another aspect, the present disclosure is directed to an article offootwear may have an upper and a sole structure secured to the upper.The sole structure may include a chamber for receiving a pressurizedfluid, the chamber having a top barrier layer and a bottom barrier layerbonded to the top barrier layer about peripheral portions of the topbarrier layer and the bottom barrier layer to define an interior voidbetween the top barrier layer and the bottom barrier layer. The chambermay also include a tensile member extending between the top barrierlayer and the bottom barrier layer, the tensile member including a firsttensile member layer, the first tensile member layer having an uppersurface and a lower surface, the upper surface of the first tensilemember layer being bonded to a lower surface of the top barrier layer; asecond tensile member layer having a lower surface bonded to the bottombarrier layer; and a plurality of tethers connecting the first tensilemember layer to the second tensile member layer. The tensile member mayinclude a first tensile member section and a second tensile membersection, the first tensile member layer extending continuously betweenthe first tensile member section and the second tensile member section.The second tensile member layer is discontinuous and includes a firsttensile member layer section and a second tensile member layer sectionseparated from the first tensile member layer section by a gap. Inaddition, a portion of the bottom barrier layer extends upward in thegap between the first tensile member layer section and the secondtensile member layer section.

In another aspect, the present disclosure is directed to a die set forforming a chamber. The die set may include a first die having asubstantially planar first die surface and a second die having asubstantially planar second die surface. The first die and the seconddie may include peripheral portions configured to compress and bondchamber barrier layers to one another when the first die and the seconddie are pressed against one another. The second die may have anelongated projection extending from the substantially planar second diesurface. Also, the elongated projection may be configured to bondportions of the chamber to one another when the first die and the seconddie are pressed against one another.

In another aspect, the present disclosure is directed to a method ofmaking an article of footwear having an upper and a sole structuresecured to the upper. The method may include forming a chamber forreceiving a pressurized fluid by assembling a stacked arrangement ofchamber components. The stacked arrangement of chamber components mayinclude a first chamber barrier layer, a second chamber barrier layer,and a tensile member extending between the first chamber barrier layerand the second chamber barrier layer. The tensile member may include afirst tensile member layer, a second tensile member layer, and aplurality of tethers connecting the first tensile member layer to thesecond tensile member layer. The second tensile member layer may includea first section and a second section separate from the first section.The method may also include bonding the first chamber barrier layer tothe second chamber barrier layer to form peripheral portions of thechamber and to define an interior void between the first chamber barrierlayer and the second chamber barrier layer. Further, the method mayinclude extending a portion of the second chamber barrier layer towardthe first tensile member layer between the first section of the secondtensile member layer and the second section of the second tensile memberlayer, pressing the portion of the second chamber barrier layer againstthe first tensile member layer. Additionally, the method may includejoining the portion of the second chamber barrier layer to the firsttensile member layer between the first section of the second tensilemember layer and the second section of the second tensile member layer,bonding the first tensile member layer to the first chamber barrierlayer, and bonding the second tensile member layer to the second chamberbarrier layer. Also, the method may include inflating the chamber with apressurized fluid, incorporating the chamber into the sole structure,and attaching the sole structure to the upper.

In another aspect, the present disclosure is directed to a method ofmaking a sole structure for an article of footwear, including forming achamber for receiving a pressurized fluid. Forming the chamber mayinclude assembling a stacked arrangement of chamber components. Thestacked arrangement of chamber components may include a first chamberbarrier layer, a second chamber barrier layer, and a tensile memberextending between the first chamber barrier layer and the second chamberbarrier layer. The tensile member may include a first tensile memberlayer, a second tensile member layer, and a plurality of tethersconnecting the first tensile member layer to the second tensile memberlayer, wherein the second tensile member layer is discontinuous suchthat a first section of the second tensile member layer is separatedfrom a second section of the second tensile member layer by a gap. Themethod may include bonding the first chamber barrier layer to the secondchamber barrier layer to form peripheral portions of the chamber and todefine an interior void between the first chamber barrier layer and thesecond chamber barrier layer. The method may also include extending aportion of the second chamber barrier layer toward the first tensilemember layer in the gap between the first section of the second tensilemember layer and the second section of the second tensile member layer,pressing the portion of the second chamber barrier layer against thefirst tensile member layer. In addition, the method may include joiningthe portion of the second chamber barrier layer to the first tensilemember layer between the first section of the second tensile memberlayer and the second section of the second tensile member layer. Themethod may further include bonding the first tensile member layer to thefirst chamber barrier layer, bonding the second tensile member layer tothe second chamber barrier layer, and inflating the chamber with apressurized fluid.

In another aspect, the present disclosure is directed to a method ofmaking a sole structure for an article of footwear, including forming achamber for receiving a pressurized fluid. Forming the chamber mayinclude assembling a stacked arrangement of chamber components. Thestacked arrangement of chamber components may include a first chamberbarrier layer, a second chamber barrier layer, and a tensile memberextending between the first chamber barrier layer and the second chamberbarrier layer, the tensile member including a first tensile memberlayer, a second tensile member layer, and a plurality of tethersconnecting the first tensile member layer to the second tensile memberlayer, wherein the second tensile member layer is discontinuous suchthat a first section of the second tensile member layer is separatedfrom a second section of the second tensile member layer by a gap. Themethod may include bonding the first chamber barrier layer to the secondchamber barrier layer to form peripheral portions of the chamber and todefine an interior void between the first chamber barrier layer and thesecond chamber barrier layer. Also, the method may include extending aportion of the second chamber barrier layer toward the first tensilemember layer in the gap between the first section of the second tensilemember layer and the second section of the second tensile member layer,pressing the portion of the second chamber barrier layer against thefirst tensile member layer. Further, the method may include joining theportion of the second chamber barrier layer to the first tensile memberlayer and inflating the chamber with a pressurized fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 shows an article of footwear according to an exemplaryembodiment.

FIG. 2 shows an exploded view of an exemplary sole structure for anarticle of footwear.

FIG. 3 shows a cross-sectional view of a portion of the sole structuretaken at section line 3-3 in FIG. 2.

FIG. 4 shows an exemplary article of footwear having a sole structureincluding a fluid-filled chamber.

FIG. 5 shows a perspective view of the chamber shown in FIG. 4.

FIG. 6 shows a cross-sectional view of a portion of the chamber taken atsection line 6-6 in FIG. 5.

FIG. 7 shows an exploded view of chamber components, and a die set forjoining portions of the chamber components to one another.

FIG. 8 shows a first process of a manufacturing method of forming thechamber shown in FIG. 6.

FIG. 9 shows a second process of a manufacturing method of forming thechamber shown in FIG. 6.

FIG. 10 shows a further stage of the second process shown in FIG. 9.

FIG. 11 shows a further step of the method of forming the chamber shownin FIG. 6.

FIG. 12 shows an assembled, cross-sectional view of the chamber formedin the method shown in FIGS. 7-11.

FIG. 13 shows an assembled, cross-sectional view of another exemplaryfluid-filled chamber.

FIG. 14 shows another die configured to perform a portion of a method offorming a chamber.

FIG. 15 shows the die of FIG. 14 with a chamber barrier layer drawnagainst it using vacuum pressure.

FIG. 16 shows an assembled, cross-sectional view of the chamber formedin the method shown in FIG. 15.

FIG. 17 shows an assembled, cross-sectional view of another exemplaryfluid-filled chamber.

FIG. 18 shows an assembled, cross-sectional view of another exemplaryfluid-filled chamber.

FIG. 19 shows the chamber of FIG. 18 in an articulated condition.

DESCRIPTION

As previously discussed, articles of athletic footwear commonly includetwo primary elements, an upper and a sole structure. The upper is oftenformed from a plurality of material elements (for example, textiles,polymer sheets, foam layers, leather, synthetic leather, and othermaterials) that are stitched or adhesively bonded together to define avoid on the interior of the footwear for comfortably and securelyreceiving a foot. More particularly, the upper forms a structure thatextends over instep and toe areas of the foot, along medial and lateralsides of the foot, and around a heel area of the foot. The upper mayalso incorporate a lacing system to adjust fit of the footwear, as wellas permit entry and removal of the foot from the void within the upper.In addition, the upper may include a tongue that extends under thelacing system to enhance adjustability and comfort of the footwear, andthe upper may incorporate a heel counter.

The sole structure generally incorporates multiple layers, including,for example, a sockliner, a midsole, and a ground-engaging outer member.The sockliner is a thin, compressible member located within the upperand adjacent to a plantar (that is, lower) surface of the foot toenhance footwear comfort. The midsole is secured to a lower surface ofthe upper and forms a middle layer of the sole structure. Many midsoleconfigurations are primarily formed from a resilient polymer foammaterial, such as polyurethane (PU) or ethyl vinyl acetate (EVA), thatextends throughout the length and width of the footwear. The midsole mayalso incorporate plates, moderators, and/or other elements that furtherattenuate forces, influence the motions of the foot, and/or impartstability, for example. The ground-engaging outer member may befashioned from a durable and wear-resistant material (for example,rubber) that includes texturing to improve traction.

Further, the sole structure may include fluid-filled chambers to providecushioning and stability. Upon inflation, such chambers experiencepressure that is evenly distributed to all portions of the inner surfaceof the bladder material from which the chamber is formed. Accordingly,the tendency is for chambers, when inflated, to take on an outwardlyrounded shape. For use as cushioning members in footwear, however, it isdesirable to provide the chambers with a relatively flat form, to serveas a platform for receiving the sole of a foot of a wearer. Thus, tolimit the expansion of the top and bottom portions of the chamber uponinflation, sole structures have been developed with chambers having oneor more tensile structures that link the top portion of the chamber tothe bottom portion of the chamber in order to maintain the chambers in asubstantially planar configuration. However, such tensile members mayprovide increased stiffness to the chambers. Accordingly, there is aneed for chamber configurations that provide tensile member-equippedfluid-filled chambers with increased flexibility.

The present disclosure is generally directed to fluid-filled chamberconfigurations including tensile members including a top sheet, a bottomsheet, and a plurality of tethers extending between the top sheet andthe bottom sheet. In order to provide flexibility to the chamber, thetop or bottom tensile member sheet may be discontinuous and a portion ofthe barrier layer of the chamber may be fixedly attached to the tensilemember sheet on the opposite side of the chamber. This configuration mayform the chamber with a reduced thickness in the area of thediscontinuity in the tensile member sheet. Due to the reduced thickness,the area of the chamber having the reduced thickness may be moreflexible than other portions of the chamber. For example, the reducedthickness may form a flex groove. Such flex grooves may be selectivelylocated at various portions of the chamber corresponding with portionsof the article of footwear sole structure that are desired to havegreater flexibility, such as the portion of the forefoot regioncorresponding with the ball of the foot.

The following discussion and accompanying figures disclose a solestructure for an article of footwear. Concepts associated with thefootwear disclosed herein may be applied to a variety of athleticfootwear types, including running shoes, basketball shoes,cross-training shoes, cricket shoes, golf shoes, soccer shoes, baseballshoes, cycling shoes, football shoes, golf shoes, tennis shoes, andwalking shoes, for example. Accordingly, the concepts disclosed hereinapply to a wide variety of footwear types.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal,” as used throughout this detaileddescription and in the claims, refers to a direction extending a lengthof a sole structure, i.e., extending from a forefoot portion to a heelportion of the sole. The term “forward” is used to refer to the generaldirection in which the toes of a foot point, and the term “rearward” isused to refer to the opposite direction, i.e., the direction in whichthe heel of the foot is facing.

The term “lateral direction,” as used throughout this detaileddescription and in the claims, refers to a side-to-side directionextending in the direction of the width of a sole. In other words, thelateral direction may extend between a medial side and a lateral side ofan article of footwear, with the lateral side of the article of footwearbeing the surface that faces away from the other foot, and the medialside being the surface that faces toward the other foot.

The term “lateral axis,” as used throughout this detailed descriptionand in the claims, refers to an axis oriented in a lateral direction.

The term “horizontal,” as used throughout this detailed description andin the claims, refers to any direction substantially parallel with theground, including the longitudinal direction, the lateral direction, andall directions in between. Similarly, the term “side,” as used in thisspecification and in the claims, refers to any portion of a componentfacing generally in a lateral, medial, forward, and/or rearwarddirection, as opposed to an upward or downward direction.

The term “vertical,” as used throughout this detailed description and inthe claims, refers to a direction generally perpendicular to both thelateral and longitudinal directions. For example, in cases where a soleis planted flat on a ground surface, the vertical direction may extendfrom the ground surface upward. It will be understood that each of thesedirectional adjectives may be applied to individual components of asole. The term “upward” refers to the vertical direction heading awayfrom a ground surface, while the term “downward” refers to the verticaldirection heading towards the ground surface. Similarly, the terms“top,” “upper,” and other similar terms refer to the portion of anobject substantially furthest from the ground in a vertical direction,and the terms “bottom,” “lower,” and other similar terms refer to theportion of an object substantially closest to the ground in a verticaldirection.

For purposes of this disclosure, the foregoing directional terms, whenused in reference to an article of footwear, shall refer to the articleof footwear in an upright position, with the sole facing groundward asit would be positioned when worn by a wearer standing on a substantiallylevel surface.

In addition, for purposes of this disclosure, the term “fixedlyattached” shall refer to two components joined in a manner such that thecomponents may not be readily separated (for example, without destroyingone or both of the components). Exemplary modalities of fixed attachmentmay include joining with permanent adhesive, rivets, stitches, nails,staples, welding or other thermal bonding, chemical or molecularbonding, and/or other joining techniques. In addition, two componentsmay be “fixedly attached” by virtue of being integrally formed, forexample, in a molding process.

As utilized herein, the term “welding” or variants thereof is defined asa securing technique between two elements that involves a softening ormelting of a polymer material within at least one of the elements suchthat the materials of the elements are secured to each other whencooled. When exposed to sufficient heat, one or more of the polymermaterials of chamber components transition from a solid state to eithera softened state or a liquid state, particularly when a thermoplasticpolymer material is utilized. When sufficiently cooled, the polymermaterials then transition back from the softened state or the liquidstate to the solid state. Based upon these properties of polymermaterials, welding processes may be utilized to form a bond or weldbetween air chamber components. Thus, the term “weld” or variantsthereof is defined as the bond, link, or structure that joins twoelements through a process that involves a softening or melting of apolymer material within at least one of the elements such that thematerials of the elements are secured to each other when cooled. Asexamples, welding may involve (a) the melting or softening of twoelements that include polymer materials such that the polymer materialsfrom each element intermingle with each other (e.g., diffuse across aboundary layer between the polymer materials) and are secured togetherwhen cooled and (b) the melting or softening of a polymer material in afirst element such that the polymer material extends into or infiltratesthe structure of a second element (e.g., infiltrates crevices orcavities formed in the second element or extends around or bonds withfilaments or fibers in the second element) to secure the two elementstogether when cooled. Welding may occur when only one element includes apolymer material or when both elements include polymer materials.Additionally, welding does not generally involve the use of stitching oradhesives, but involves directly bonding elements to each other withheat. In some situations, however, adhesives may be utilized tosupplement the weld or the joining of the elements through welding.

FIG. 1 depicts an embodiment of an article of footwear 100, which mayinclude a sole structure 105 and an upper 110 secured to sole structure105. As shown in FIG. 1 for reference purposes, footwear 100 may bedivided into three general regions, including a forefoot region 130, amidfoot region 135, and a heel region 140. Forefoot region 130 generallyincludes portions of footwear 100 corresponding with the toes and thejoints connecting the metatarsals with the phalanges. Midfoot region 135generally includes portions of footwear 100 corresponding with an archarea of the foot. Heel region 140 generally corresponds with rearportions of the foot, including the calcaneus bone. Forefoot region 130,midfoot region 135, and heel region 140 are not intended to demarcateprecise areas of footwear 100. Rather, forefoot region 130, midfootregion 135, and heel region 140 are intended to represent generalrelative areas of footwear 100 to aid in the following discussion.

Since sole structure 105 and upper 110 both span substantially theentire length of footwear 100, the terms forefoot region 130, midfootregion 135, and heel region 140 apply not only to footwear 100 ingeneral, but also to sole structure 105 and upper 110, as well as theindividual elements of sole structure 105 and upper 110. Footwear 100may be formed of any suitable materials. In some configurations, thedisclosed footwear 10 may employ one or more materials disclosed inLyden et al., U.S. Pat. No. 5,709,954, issued Jan. 20, 1998, the entiredisclosure of which is incorporated herein by reference.

Upper 110 may include one or more material elements (formed, forexample, of textiles, foam, leather, and/or synthetic leather), whichmay be stitched, adhesively bonded, molded, or otherwise formed todefine an interior void configured to receive a foot. The materialelements may be selected and arranged to selectively impart propertiessuch as durability, air-permeability, wear-resistance, flexibility, andcomfort. Upper 110 may alternatively implement any of a variety of otherconfigurations, materials, and/or closure mechanisms.

Sole structure 105 may have a configuration that extends between upper110 and the ground and may be secured to upper 110 in any suitablemanner. For example, sole structure 105 may be secured to upper 110 byadhesive attachment, stitching, welding, or any other suitable method.Sole structure 105 may include provisions for attenuating groundreaction forces (that is, cushioning and stabilizing the foot duringvertical and horizontal loading). In addition, sole structure 105 may beconfigured to provide traction, impart stability, and/or limit variousfoot motions, such as pronation, supination, and/or other motions.

The configuration of sole structure 105 may vary significantly accordingto one or more types of ground surfaces on which sole structure 105 maybe used. For example, the disclosed concepts may be applicable tofootwear configured for use on indoor surfaces and/or outdoor surfaces.The configuration of sole structure 105 may vary based on the propertiesand conditions of the surfaces on which footwear 100 is anticipated tobe used. For example, sole structure 105 may vary depending on whetherthe surface is harder or softer. In addition, sole structure 105 may betailored for use in wet or dry conditions.

Sole structure 105 may include multiple components, which mayindividually and/or collectively provide footwear 100 with a number ofattributes, such as support, rigidity, flexibility, stability,cushioning, comfort, reduced weight, traction, and/or other attributes.As shown in FIG. 1, sole structure 105 may include a ground-contactingouter member 120. In addition, in some embodiments, sole structure 105may also include a midsole 115 disposed between outer member 120 andupper 110.

Outer member 120 may include an outer surface 125 exposed to the ground.Outer member 120 may include various features configured to providetraction. For example, in some embodiments, outer surface 125 mayinclude a patterned tread, as shown in FIG. 1. In some embodiments,outer member 120 may include one or more ground-engaging cleat membersextending from outer surface 125.

Outer member 120 may be formed of suitable materials for achieving thedesired performance attributes. For example, outer member 120 may beformed of any suitable polymer, composite, and/or metal alloy materials.Exemplary such materials may include thermoplastic and thermosetpolyurethane, polyester, nylon, polyether block amide, alloys ofpolyurethane and acrylonitrile butadiene styrene, carbon fiber,poly-paraphenylene terephthalamide (para-aramid fibers, e.g., Kevlar®),titanium alloys, and/or aluminum alloys. In some embodiments, outermember 120 may be fashioned from a durable and wear-resistant material(for example, rubber). Other suitable materials, includingfuture-developed materials, will be recognized by those having skill inthe art. Materials and configurations for outer member 120 may beselected according to the type of activity for which footwear 100 isconfigured.

Midsole 115 may have any suitable configuration and may providecushioning and stability. For example, in some embodiments, midsole 115may be formed of a compressible material, such as a resilient polymerfoam material, examples of which may include polyurethane (PU) or ethylvinyl acetate (EVA). In some embodiments, midsole 115 may extendthroughout the length and width of footwear 100. In some embodiments,midsole 115 may also incorporate incompressible plates, moderators,and/or other elements that further attenuate forces, influence themotions of the foot, and/or impart stability, for example.

In some embodiments, the article of footwear may be provided withfeatures that provide flexibility to the sole of the footwear. Forexample, in some embodiments, one or more components of the solestructure may have a flex groove that facilitates bending of the sole.In some embodiments, the sole structure may include a plurality of flexgrooves in the forefoot region of the footwear. Also, the sole structuremay include layered components, including, for example, an outer member(outsole), a midsole, and a cushioning element, such as a chamber filledwith a pressurized fluid. In order to facilitate bending of the layeredstructure, the layered components may each have corresponding flexgrooves.

FIG. 2 illustrates a portion of footwear 100, including sole structure105. As shown in FIG. 2, outer member 120 may have an inner surface 155opposite outer surface 125. Inner surface 155 may be disposed closer toa wearer's foot than outer surface 125 when footwear 100 is worn by thewearer. That is, inner surface 155 may be disposed upward of outersurface 125. Outer member 120 may include a first flex groove portion145 and a second flex groove portion 150. First flex groove portion 145may include a first elongate recess 160 in outer surface 125 of outermember 120. Elongate recess 160 may be formed by an upward curvature inouter surface 125 of outer member 120, which extends in an upwarddirection (that is, toward the wearer's foot when footwear 100 is wornby the wearer).

In some embodiments, outer member 120 may have a substantiallyconsistent thickness. Due to the consistent thickness of outer member120, inner surface 155 of outer member 120 may also include an upwardcurvature, extending in an upward direction (that is, toward thewearer's foot when footwear 100 is worn by the wearer), thus forming anelongate rib 165 in first flex groove portion 145. Accordingly, bothouter surface 125 and inner surface 155 of outer member 120 may curvetowards the wearer's foot when footwear 100 is worn by a wearer.

First flex groove portion 145 may separate a first outer member forefootregion 170 from a second outer member forefoot region 175. In someembodiments, first flex groove 145 may form a thinner portion of outermember 120 (in a vertical direction) than other portions of outer member120 (such as first outer member forefoot region 170 and second outermember forefoot region 175), in order to provide increased flexibilityof outer member 120 in this area.

In some embodiments, first flex groove portion 145 may extend in alateral direction. For example, footwear 100, and therefore outer member120, may have a medial side 131 and a lateral side 132. As shown in FIG.2, elongate recess 160 and elongate rib 165 of first flex groove portion145 may extend substantially from a medial edge 133 of outer member 120to a lateral edge 134 of outer member 120. Further, in some embodiments,first flex groove portion 145 may extend completely from medial edge 133to lateral edge 134, as shown in FIG. 2.

In some embodiments, outer member 110 may also include one or moreadditional flex groove portions, such as second flex groove portion 150,as shown in FIG. 2. Second flex groove portion 150 may separate secondforefoot region 175 from a third forefoot region 180. Second flex grooveportion 150 may form a thinner portion of outer member 110 than otherportions of outer member 110, in order to provide increased flexibilityof outer member 110. Second flex groove portion 150 may include a secondelongate recess 185 in outer surface 125 of outer member 120. As withfirst elongate recess 160, elongate recess 185 may extend in an upwarddirection (that is, toward the wearer's foot when footwear 100 is wornby the wearer). Also similar to first flex groove portion 145, secondflex groove portion 150 may also include a second elongate rib 190formed by the upward curvature of inner surface 155 of outer member 120.

As shown in FIG. 2, midsole 115 may have a first midsole surface 200 anda second midsole surface 205 opposite first midsole surface 200. In someembodiments, midsole 115 may include a third flex groove portion 210.Third flex groove portion 210 may include a third elongate recess 215 insecond midsole surface 205. Third elongate recess 215 may extend in anupward direction (that is, toward a wearer's foot when footwear 100 isworn by the wearer). Third flex groove portion 210 may also include athird elongate rib 215 in first midsole surface 200. Third elongate rib215 may extend in an upward direction (that is, toward the wearer's footwhen footwear 100 is worn by the wearer).

As further shown in FIG. 2, midsole 115 may also include a fourth flexgroove portion 225. Fourth flex groove portion 225 may include a fourthelongate recess 230 in second midsole surface 205. Fourth elongaterecess 230 may extend in an upward direction (that is, toward a wearer'sfoot when footwear 100 is worn by the wearer). Fourth flex grooveportion 225 may also include a fourth elongate rib 235 in first midsolesurface 200. Fourth elongate rib 235 may extend in an upward direction(that is, toward the wearer's foot when footwear 100 is worn by thewearer).

As shown in FIG. 2, in some embodiments, third elongate recess 215 insecond midsole surface 205 may receive first elongate rib 165 of firstflex groove portion 145 of outer member 120. Similarly, in someembodiments, fourth elongate recess 230 in second midsole surface 205may receive second elongate rib 190 of second flex groove portion 150 ofouter member 120. Thus, first elongate rib 165 and second elongate rib190 may be disposed in a nested relationship with third elongate recess215 and fourth elongate recess 230, respectively.

In some embodiments, the sole structure may include one or moreadditional components that provide cushioning. For example, in someembodiments, the sole structure may include a chamber filled withpressurized gases. In some configurations, the chamber may includeelongate indentations configured to receive elongate ribs in the midsoleor outsole member and to provide the chamber with flexibility.

As shown in FIG. 2, in some embodiments, sole structure 105 may includea chamber 240 for receiving a pressurized fluid. In some embodiments,chamber 240 may include a first chamber barrier layer 245 and a secondchamber barrier layer 250. As shown in FIG. 2, in some embodiments,first chamber barrier layer 245 may be a top barrier layer and secondchamber barrier layer 250 may be a bottom barrier layer. Second chamberbarrier layer 245 may be bonded to first chamber barrier layer 240 aboutperipheral portions of first chamber barrier layer 240 and secondchamber barrier layer 245 to define an interior void between firstchamber barrier layer 240 and second chamber barrier layer 245.

Chamber 240 may be formed from a polymer or other bladder material thatprovides a sealed barrier for enclosing a fluid. As noted above, thebladder material may be transparent. A wide range of polymer materialsmay be utilized for chamber 240. In selecting materials for chamber 240,engineering properties of the material (e.g., tensile strength, stretchproperties, fatigue characteristics, dynamic modulus, and loss tangent)as well as the ability of the material to prevent the diffusion of thefluid contained by chamber 240 may be considered. When formed ofthermoplastic urethane, for example, the outer barrier of chamber 240may have a thickness of approximately 1.0 millimeter, but the thicknessmay range from 0.25 to 2.0 millimeters or more, for example.

In addition to thermoplastic urethane, examples of polymer materialsthat may be suitable for chamber 240 include polyurethane, polyester,polyester polyurethane, and polyether polyurethane. Chamber 240 may alsobe formed from a material that includes alternating layers ofthermoplastic polyurethane and ethylene-vinyl alcohol copolymer, asdisclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell, et al.A variation upon this material may also be utilized, wherein a centerlayer is formed of ethylene-vinyl alcohol copolymer, layers adjacent tothe center layer are formed of thermoplastic polyurethane, and outerlayers are formed of a regrind material of thermoplastic polyurethaneand ethylene-vinyl alcohol copolymer. Another suitable material forchamber 240 is a flexible microlayer membrane that includes alternatinglayers of a gas barrier material and an elastomeric material, asdisclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk, et al.Additional suitable materials are disclosed in U.S. Pat. Nos. 4,183,156and 4,219,945 to Rudy. Further suitable materials include thermoplasticfilms containing a crystalline material, as disclosed in U.S. Pat. Nos.4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyesterpolyol, as disclosed in U.S. Pat. Nos. 6,013,340; 6,203,868; and6,321,465 to Bonk, et al. The patents listed in this paragraph areincorporated herein by reference in their entirety.

The fluid within chamber 240 may range in pressure from zero tothree-hundred-fifty kilopascals (i.e., approximately fifty-one poundsper square inch) or more. In some configurations of sole structure 105,a suitable pressure for the fluid may be a substantially ambientpressure. That is, the pressure of the fluid may be within fivekilopascals of the ambient pressure of the atmospheric air surroundingfootwear 100. The pressure of fluid within chamber 240 may be selectedto provide desirable performance attributes. For example, higherpressures may provide a more responsive cushioning element, whereaslower pressures may provide more ground force attenuation (a softercushion). The pressure of fluid within chamber 240 may be selected towork in concert with other cushioning elements of footwear 100, such asfoam members and/or an insole (not shown). In some embodiments theinsole may be formed of a compressible material.

In some configurations, chamber 240 may be inflated with substantiallypure nitrogen. Such an inflation gas promotes maintenance of thepressure within chamber 240 through diffusion pumping, whereby thedeficiency of other gases (besides nitrogen), such as oxygen, withinchamber 240 biases the system for inward diffusion of such gasses intochamber 240. Further, bladder materials, such as those discussed above,may be substantially impermeable to nitrogen, thus preventing the escapeof the nitrogen from chamber 240.

In some configurations, relatively small amounts of other gases, such asoxygen or a mixture of gasses, such as air, may be added to the nitrogenoccupying most of the volume within chamber 240. In addition to air andnitrogen, the fluid contained by chamber 240 may includeoctafluoropropane or be any of the gasses disclosed in U.S. Pat. No.4,340,626 to Rudy, such as hexafluoroethane and sulfur hexafluoride, forexample. In some configurations, chamber 240 may incorporate a valvethat permits the individual to adjust the pressure of the fluid. Inother configurations, chamber 240 may be incorporated into a fluidsystem, as disclosed in U.S. Pat. No. 7,210,249 to Passke, et al., as apump chamber or a pressure chamber. In order to pressurize chamber 240or portions of chamber 240, the general inflation methods disclosed inHensley et al., U.S. Pat. No. 8,241,450, issued Aug. 14, 2012, andentitled “Method For Inflating A Fluid-Filled Chamber,” and Schindler etal., U.S. Patent Application Publication No. US 2009/0151196, publishedJun. 18, 2009, entitled “Article Of Footwear Having A Sole StructureWith A Fluid-Filled Chamber” may be utilized. The patents and publishedpatent applications listed in this paragraph are incorporated herein byreference in their entirety.

In some embodiments, the chamber may include one or more features thatlimit the expansion of the top and bottom portions of the chamber uponinflation. For example, in some embodiments, the chamber may include oneor more tensile structures that link the top portion of the chamber tothe bottom portion of the chamber. Such tensile structures may besubstantially inelastic (or may have a limited elasticity) such that,when the chamber is inflated causing the top and bottom portions of thechamber to be biased apart from one another, the tensile structureslimit the distance by which the top and bottom portions may be separatedduring inflation. Accordingly, the tensile members may enable thebladder to retain its intended, substantially planar shape.

As shown in FIG. 2, a tensile member 255 may extend between firstchamber barrier layer 245 and second chamber barrier layer 250. Tensilemember 255 may include a first tensile member layer 260 bonded to firstchamber barrier layer 245. In addition, tensile member 255 may alsoinclude a second tensile member layer 265 bonded to second chamberbarrier layer 260. Also, tensile member 255 may include a plurality oftethers 270 connecting first tensile member layer 260 to second tensilemember layer 265. The outward force of pressurized fluid within chamber240 places tethers 270 in tension and restrains further outward movementof first tensile member layer 260 and first chamber barrier layer 245away from second tensile member layer 265 and second chamber barrierlayer 250.

Tensile member 255 may have any configuration suitable for limiting thedistance between first chamber barrier layer 245 and second chamberbarrier layer 250 of chamber 240 when inflated. For example, tensilemember 255 may have any of the configurations disclosed in Dua, U.S.Pat. No. 8,151,486, issued Apr. 10, 2012, and entitled “Fluid-FilledChamber with a Textile Tensile Member;” Peyton et al., U.S. PatentApplication Publication No. 2011/0131831, published Jun. 9, 2011, andentitled “Tethered Fluid-Filled Chambers,”; and Hazenberg et al., U.S.Patent Application Publication No. 2013/0266773, published Oct. 10,2013, and entitled “Spacer Textile Materials and Methods forManufacturing the Spacer Textile Materials,” the entire disclosures ofwhich are incorporated herein by reference.

In some configurations, tethers 270 may include a plurality ofsubstantially planar slats. In some configurations, such slats may bearranged in a substantially vertical orientation. In other embodiments,such slats may be angled with respect to first chamber barrier layer 245and second chamber barrier layer 250. Further, such slats may beoriented in any suitable direction. For example, in some embodiments,the slats may be oriented in a substantially lateral direction. In otherembodiments, the slats may be oriented in a substantially longitudinaldirection. Other orientations are also possible. Tethers 270 may haveany of the planar configurations disclosed in Dua, U.S. Pat. No.8,151,486, issued Apr. 10, 2012, and entitled “Fluid-Filled Chamber witha Textile Tensile Member.”

In some configurations, tethers 270 may include a plurality ofstrand-like members having a substantially one-dimensionalconfiguration. For example, tethers 270 may each have a length betweenfirst tensile member layer 260 and second tensile member 265. Thislength may be substantially greater than the width or thickness of theone-dimensional tethers. Tethers 270 may have any of the one-dimensionalconfigurations disclosed in Peyton et al., U.S. Patent ApplicationPublication No. 2011/0131831, published Jun. 9, 2011, and entitled“Tethered Fluid-Filled Chambers.”

Tethers 270 may be formed of any suitable material. For example in someembodiments, tethers 270 may be formed of a polymer material. In someembodiments, tensile member 255 may be formed of a three-dimensionalfabric (3-D fabric). Tensile member 255 may be formed as a unitary(i.e., one-piece) textile element having the configuration of aspacer-knit textile. A variety of knitting techniques may be utilized toform tensile member 255 and impart a specific configuration (e.g.,taper, contour, length, width, thickness) to tensile member 255. Ingeneral, knitting involves forming courses and wales of intermeshedloops of a yarn or multiple yarns. In production, knitting machines maybe programmed to mechanically-manipulate yarns into the configuration oftensile member 255. That is, tensile member 255 may be formed bymechanically-manipulating yarns to form a one-piece textile element thathas a particular configuration. The two major categories of knittingtechniques are weft-knitting and warp-knitting. Whereas a weft-knitfabric utilizes a single yarn within each course, a warp-knit fabricutilizes a different yarn for every stitch in a course. In someembodiments, tensile member 255 may be formed using double needle barRaschel knitting. In some embodiments, tensile member 255 may be formedusing configurations disclosed in Hazenberg et al., U.S. PatentApplication Publication No. 2013/0266773, published Oct. 10, 2013, andentitled “Spacer Textile Materials and Methods for Manufacturing theSpacer Textile Materials.”

In some embodiments, all of tethers 270 may have substantially the samelength, thus providing tensile member 255 with a substantially constantthickness. In other embodiments, tethers 270 may have different lengths.In some embodiments, first tensile member layer 260 and second tensilemember layer 260 may each have a generally continuous and planarconfiguration. In some embodiments, first tensile member layer 260 andsecond tensile member layer 265 may be substantially parallel to oneanother. In other embodiments, tensile member 255 may have a taperedconfiguration. For example, in some embodiments, tensile member 255 mayhave a tapered configuration between heel region 140 and forefoot region130. In order to impart the tapered configuration, the lengths oftethers 270 may decrease between heel region 140 and forefoot region130. Exemplary tapered chamber configurations are disclosed in Dua, U.S.Pat. No. 8,151,486, issued Apr. 10, 2012, and entitled “Fluid-FilledChamber with a Textile Tensile Member.”

In some embodiments, one or both of first tensile member layer 260 andsecond tensile member layer 260 may have a contoured configuration. Forexample, in some embodiments, first tensile member layer 260 may have aconcave configuration to conform to the anatomical shapes of the foot. Adepression in heel region 140 may cradle the heel of a wearer and moreevenly distribute contact forces between chamber 240 and the foot of thewearer. Exemplary contoured chamber configurations are disclosed in Dua,U.S. Pat. No. 8,151,486, issued Apr. 10, 2012, and entitled“Fluid-Filled Chamber with a Textile Tensile Member;” and Peyton et al.,U.S. Patent Application Publication No. 2011/0131831, published Jun. 9,2011, and entitled “Tethered Fluid-Filled Chambers.”

In some embodiments, tensile member 255 may include multiple sections.For example, as shown in FIG. 2, tensile member 255 may include a firsttensile member section 281 corresponding with a first chamber portion285. Tensile member 255 may also include a second tensile member section282 corresponding with a second chamber portion 290. Further, tensilemember 255 may include a third tensile member section 283 correspondingwith a third chamber portion 295.

In some embodiments, midsole 115 may include a recess 300 configured toreceive chamber 240. First chamber portion 281 may be received by afirst portion of recess 300 including a heel recess region 305, amidfoot recess region 310, and a first forefoot recess region 315. Thisfirst portion of recess 300 may be separated from a second forefootrecess region 320 by third elongate rib 220. Second forefoot recessregion 320 may receive second chamber portion 290. Further, secondforefoot recess region 320 may be separated from a third forefoot recessregion 325 by fourth elongate rib 235. Third forefoot recess region 325may receive third chamber portion 295.

As shown in FIG. 2, spaces between the chamber portions may formindentations. For example, the space between first chamber portion 285and second chamber portion 290 may form a first elongate indentation275, as shown in FIG. 2. Similarly, the space between second chamberportion 290 and third chamber portion 295 may form a second elongateindentation 280. In some embodiments, first elongate indentation 275 mayreceive third elongate rib 220 of third flex groove portion 210 ofmidsole 115, in a nesting relationship. Second elongate indentation 275may receive fourth elongate rib 235 of midsole 115, also in a nestingrelationship.

The nested relationships between the ribs of outer member 120 and therecesses of midsole 115, as well as the nesting relationships betweenthe ribs of midsole 115 and the indentations of chamber 240, may enablesole structure 105 to have a thinner profile. That is, the overallthickness of sole structure 105 as formed by the combination of solestructure components (outer member 120, midsole 115, and chamber 240)may be reduced. For example, a wearer's foot may be located lower to theground than if the entirety of midsole 115 were located at the raisedheight of first elongate rib 165 and second elongate rib 190. Similarly,a wearer's foot may be located lower to the ground than if the entiretyof chamber 240 were located at the raised height of third elongate rib220 and fourth elongate rib 235.

The reduced overall thickness of sole structure 105 provided by thenesting relationships of sole structure components may increase thestability and responsiveness of sole structure 105. Alternatively, oradditionally, the reduced overall thickness, which is made possible bythe nesting relationships of sole structure components, may provide morespace for sole structure components. For example, because most ofmidsole 115 may be positioned lower to the ground, thicker cushioningelements, such as chamber 240, may be utilized in conjunction withmidsole 115 without unduly raising the footbed of footwear 110.

As shown in FIG. 2, first tensile member layer 260 may extendcontinuously between first tensile member section 281, second tensilemember section 282, and third tensile member section 282. Second tensilemember layer 265 may be discontinuous. For example, second tensilemember layer 265 may include a first tensile member layer section 271, asecond tensile member layer section 272, and a third tensile memberlayer 273. First tensile member layer section 271 may be separated fromsecond tensile member layer section 272 by a gap corresponding withfirst indentation 275. Second tensile member layer section 272 may beseparated from third tensile member layer section 273 by a gapcorresponding with second indentation 280.

It will be noted that, although first elongate indentation 275 andsecond elongate indentation are shown in FIG. 2 as being substantiallylaterally oriented, in some embodiments, the configuration of elongateindentations in chamber 240 may have any suitable orientation. Inaddition, the number of elongate indentations may vary. Additionalelongate indentations may provide chamber 240 with additionalflexibility.

FIG. 3 is a cross-sectional view taken at section line 3-3 of FIG. 2. Inparticular, FIG. 3 illustrates a cross-sectional view of chamber 240through second indentation 280. As shown in FIG. 3, first chamberbarrier layer 245 extends across second chamber portion 290 and thirdchamber portion 295. As discussed above, first tensile member layer 260may extend continuously between second tensile member section 282 andthird tensile member section 283. Further, as also discussed above,second tensile member layer 265 may include second tensile member layersection 272 and a third tensile member layer section 273, which may beseparated by a gap 330.

In order to provide second tensile member layer 265 with separatesections, a portion of first tensile member layer 260 may be omitted toform gap 330. In some embodiments, the portions of material may beomitted during manufacturing of tensile member 255. In some embodiments,the portions of material may be removed from tensile member 255. Forexample, in some embodiments, the material may be removed by cuttingtools, such as lasers, blades, cutting wheels, shears, or other suitablecutting implements.

As shown in FIG. 3, a portion 335 of second chamber barrier layer 250extends upward in gap 330 toward first tensile member layer 260 betweensecond tensile member layer section 272 and third tensile member layersection 273 of second tensile member layer 265. Portion 335 of secondchamber barrier layer 250 that extends toward first tensile member layer260 may be joined to first tensile member layer 260. That is, portion335 of the bottom barrier layer extends upward between the secondtensile member layer section 272 and third tensile member layer section273 of second tensile member layer 265 and joins to a lower surface 340of first tensile member layer 260.

In order to facilitate this joinder of first tensile member layer 260with second chamber barrier layer 250, first tensile member layer 260may be formed of a material that is suited for bonding with secondchamber barrier layer 250. In some embodiments, first tensile memberlayer 260 may be formed of a material that is configured to provideadded strength in order to compensate for at least some of the effect ofhaving a portion of second tensile member layer 265 omitted. Such addedstrength may be provided by selecting a stronger material and/or byincreasing the amount of material used (e.g., the thickness) for firsttensile member layer 260. In some embodiments, first tensile memberlayer 260 may be constructed in a manner that provides increasedstrength. For example, in some embodiments where first tensile memberlayer 260 is a textile, different knitting/weaving processes may be usedto provide added strength.

By joining portion 335 of second chamber barrier layer 250 to firsttensile member layer 260, several advantages may be provided. Forexample, this configuration provides chamber 240 with flexibility. Thisflexibility is provided by several aspects of this configuration. Byjoining portion 335 of second chamber barrier layer 250 to first tensilemember layer 260, the thickness of chamber 240 may be reduced in thatarea. As shown in FIG. 3, chamber 240 may have a first thickness 345 atthe junction between portion 335 of second chamber barrier layer 250 andfirst tensile member layer 260. Chamber 240 may have a second thickness350 over a majority of chamber 240. As shown in FIG. 3, first thickness345 of chamber 240 may be less than second thickness of chamber 240.This reduced thickness may act as a living hinge, thus enabling flexionbetween second chamber portion 290 and third chamber portion 295.

Joining portion 335 of second chamber barrier layer 250 to first tensilemember layer 260 also defines second indentation 280, which may receiveflex groove portions of mating sole structure components. This enablesthe sole structure components to have a nesting relationship thatprovides the sole structure with a thinner profile. As discussed above,this thinner profile may provide the footwear with stability andresponsiveness.

In addition, although second tensile member layer 265 is separated intomultiple sections, such as second tensile member layer section 272 andthird tensile member layer section 273, first tensile member layer 260remains continuous across multiple sections of chamber 240. Thus,tensile member 255 may be a fully pre-formed structure prior to assemblyinto chamber 240. Tensile member 255 being a fully pre-formed structuremay facilitate positioning of tensile member 255 during assembly,because there are no separate pieces that may become out of place withrespect to one another when pressed between first chamber barrier layer245 and second chamber barrier layer 250.

In some embodiments, the sole structure may omit the midsole layerbetween the chamber and outsole. That is, the chamber may be secureddirectly to the outer member of the sole structure. In such embodiments,the indentations of the chamber may receive the elongate ribs of theflex groove portions of the outer member of the sole structure. In somecases, such a configuration may provide the sole structure with an evenlower profile. In some embodiments, a midsole may be located above thechamber. That is, in some cases, the chamber may be disposed between themidsole and the outsole.

FIG. 4 shows an article of footwear 400. Footwear 400 may include a solestructure 405 secured to an upper 410. Sole structure 405 may include anouter member 415 and a chamber 440. FIG. 4 shows footwear 400 in anarticulated position with the heel portion raised in the direction of anarrow 430. This articulation is indicated by flexion of a first flexgroove portion 420 and a second flex groove portion 425 of outer member415. In addition, this articulation also involves the flexion of a firstindentation 475 and a second indentation 480 in chamber 440.

Like chamber 240 discussed above, chamber 440 may include a firstchamber barrier layer 445 and a second chamber barrier layer 450. Inaddition, chamber 440 may also include a tensile member 455 bonded tofirst chamber barrier layer 445 and second chamber barrier layer 450,and configured to limit the spacing between these barrier layers whenchamber 440 is pressurized. Tensile member 455 may include a firsttensile member layer 460 and a second tensile member layer 465. Tensilemember 455 may also include a plurality of tethers 470 connecting firsttensile member layer 460 to second tensile member layer 465.Characteristics of the components of footwear 400 and chamber 440discussed above may be substantially similar to corresponding componentsdiscussed above regarding other embodiments.

As shown in FIG. 4, wherein the portion of second chamber barrier layer450 that extends toward first tensile member layer 460 defines firstelongate indentation 475 in chamber 440. As shown in FIG. 4, firstelongate indentation 475 may receive a first elongate rib formed byfirst flex groove portion 420 of outer member 415. Similarly, secondelongate indentation 480 may receive a second elongate rib formed bysecond flex groove portion 425.

In some embodiments, chambers having multiple sections may beincorporated into sole structures that may or may not include a midsole.Accordingly, in some embodiments, the sole structure may include amidsole that includes elongate ribs that may nest within elongateindentations in the chamber. In other embodiments, the sole structuremay include an outer member that includes elongate ribs that may nestwithin elongate indentations in the chamber. Thus, the sole structuremay include an additional sole structure component, the additional solestructure component including at least one of a midsole and an outermember exposed to the ground. The additional sole structure componentmay have an upper surface and a lower surface. Further, the additionalsole structure component may have a flex groove portion including anelongate recess in the bottom surface and a corresponding elongate ribon the upper surface. The portion of the bottom barrier layer thatextends upward between a first section and a second section of a secondtensile member layer may define an elongate indentation in the chamberthat receives the elongate rib of the flex groove portion of theadditional sole structure component.

FIG. 5 illustrates an isolated view of chamber 440 shown in anarticulated configuration. As shown in FIG. 5, second tensile memberlayer 465 may be formed as multiple separate sections, such as a firsttensile member layer section 501, a second tensile member layer section502, and a third tensile member layer section 503. First elongateindentation 475 of chamber 440 may be located between first tensilemember layer section 501 from second tensile member layer section 502.Similarly, second elongate indentation 480 may be located between secondtensile member layer section 502 and third tensile member layer section503. As shown in FIG. 5, flexion of chamber 440 in the direction ofarrow 485 may result in the articulation of chamber 440 at a first flexline 490 corresponding with first elongate indentation 475 and a secondflex line 495 corresponding with second elongate indentation 480.

FIG. 6 is a cross-sectional view of chamber 440 taken at section line6-6 in FIG. 5. As shown in FIG. 6, a portion 505 of second chamberbarrier layer 450 may extend upward between second tensile member layersection 502 and third tensile member layer section 503. As further shownin FIG. 6, section 505 of second chamber barrier layer 450 may be joinedto a lower surface 510 of first tensile member layer 460. FIG. 6 furtherillustrates the articulation of chamber 440 by flexion at second flexline 495. As shown in FIG. 6, chamber 440 may be flexed at an angleillustrated by angle 515. Angle 515 is an exemplary angle and is notintended to indicate the limit to which chamber 440 may be flexed.

FIG. 7 shows an exploded view of chamber components, and a die set forjoining portions of the chamber components to one another. Inparticular, FIG. 7 illustrates an exploded view of chamber 440. As shownin FIG. 7 chamber 440 may include a first adhesive layer 730 betweenfirst chamber barrier layer 445 and first tensile member layer 460 and asecond adhesive layer 735 between second chamber barrier layer 450 andsecond tensile member layer 465. First adhesive layer 730 and secondadhesive layer 735 may be any suitable adhesive for joining the barrierlayers to the tensile member layers. For example, in some embodiments,adhesive layer 730 and second adhesive layer 735 may include a hot meltadhesive. Adhesive layer 730 and second adhesive layer 735 are omittedfrom other drawings of the application for purposes of clarity.

For purposes of illustration, FIG. 7 shows a portion of chamber 440corresponding with that shown in FIG. 6. In FIG. 7, however, chamber 440is oriented in an opposite direction than in FIG. 6. That is, while thecompleted chamber may be oriented with the flex groove facing downward,as shown in FIG. 6, the chamber may be assembled upside down during themanufacturing process, as described further below.

In some embodiments, tensile member 455 may have two sections. As shownin FIG. 7, second tensile member layer 465 may be discontinuous betweenthe two sections. For example, as shown in FIG. 7, second tensile memberlayer 465 may include a first portion 502 and a second portion 503separate from first portion 502 by a gap 725. In contrast, first tensilemember layer 460 may extend continuously between the first tensilemember section and the second tensile member section, as shown in FIG.7.

As shown in FIG. 7, a first process of the manufacturing method mayutilize a first die set 700. First die set 700 may include a first die705 and a second die 710. First die set 700 may be configured to drawfirst barrier layer 445 against first die 705 using vacuum pressure. Forexample, in some embodiments, first die 705 may include one or more airpassages 711 through which air may be removed to create vacuum pressure(i.e., reduced pressure) in order to draw first barrier layer 445against first die 705, thereby conforming first barrier layer 445 to thecontours of first die 705. Similarly, second die 710 may include one ormore air passages 712 through which air may be removed in order to drawsecond chamber barrier layer 450 against second die 710, therebyconforming second chamber barrier layer 450 to the contours of seconddie 710. For example, second die 710 may include an elongate projection740. By drawing second chamber barrier layer 450 against second die 710,second chamber barrier layer 450 may conform to the contours of elongateprojection 740.

Arranging the plurality of chamber components in a stacked arrangementmay involve locating tensile member 455 between first chamber barrierlayer 445 and second chamber barrier layer 450. The method may includeplacing the stacked arrangement of chamber components into first die set700. In some embodiments, the stacked arrangement of chamber componentsmay be placed within the die set together. In some embodiments, thestacked arrangement of chamber components may be individually insertedinto the die set. For example, in some embodiments, first chamberbarrier layer 445 may be drawn against first die 705 using vacuumpressure, and second chamber barrier layer 450 may be drawn againstsecond die 710. Then, tensile member 455 may be placed between firstchamber barrier layer 445 and second chamber barrier layer 450.

In some embodiments, the method of forming chamber 440 may include twoprocesses. FIGS. 7 and 8 illustrate a first process of the method. Thefirst process may include bonding first chamber barrier layer 445 to thesecond chamber barrier layer 450 to form peripheral portions of thechamber.

The first process may also include joining a portion of second chamberbarrier layer 450 to first tensile member layer 460. In someembodiments, not only may the first die set be used to join the chamberbarrier layers to the tensile member, but the first die set may also beused to seal the peripheral portions of the chamber barrier layers.First die 705 may include a first peripheral die projection 905extending toward second die 710. Second die 710 may include a secondperipheral die projection 910 extending toward first die 705. In someembodiments, the bonding and joining steps of the first process may beperformed simultaneously in first die set 700 as part of the firstprocess.

In order to perform these bonding and joining steps, the first processmay include applying pressure to the stacked arrangement of chambercomponents to join portions of the chamber components to one another.For example, the method may include applying heat and pressure bycompressing a stacked arrangement of components of chamber 440 betweenfirst die 705 and second die 710. This compression may be accomplishedby applying force with first die 705 in a direction indicated by a firstarrow 715 and by applying an opposite force with second die 710 in anopposite direction indicated by a second arrow 720.

FIG. 8 illustrates the use of first die set 700 to bond portions of thestacked arrangement of chamber components shown in FIG. 7. When pressureis applied with first die 705 and second die 710, elongate projection740 may fixedly attach second chamber barrier layer 450 to first tensilemember layer 460 in gap 725. As shown in FIG. 8, applying pressure tothe stacked arrangement of chamber components with first die 705 andsecond die 710 may extend elongate projection 740 of second die 710 intogap 725 between first tensile member layer section 502 and secondtensile member layer section 503 and presses second chamber barrierlayer 450 against first tensile member layer 460.

In addition, as also shown in FIG. 8, when first die 705 and second die710 are compressed together, a first peripheral barrier layer portion offirst chamber barrier layer 445 may be compressed against and joined toa second peripheral barrier layer portion of second chamber barrierlayer 450 between first peripheral die projection 905 and secondperipheral die projection 910 to form a bonded peripheral edge 925 ofchamber 440.

As shown in FIG. 8, the height of elongate projection 740 may be tallenough that, when elongate projection 740 engages against first tensilemember layer 460, the opposing surfaces of first die 705 and second die710 may be separated by a first distance 805. This distance 805 may begreater than the thickness of the stacked arrangement of chambercomponents. Accordingly, while second chamber barrier layer is heldagainst second die 710, second tensile member layer 465 may rest on thebottom of the cavity within die set 700 under the influence of gravity.Therefore, in FIG. 8, tethers 470 are shown in an unextended orslackened condition. Because of this die set configuration, tensilemember 455 is not bonded to first barrier layer 445 or second barrierlayer 450 during this first process of the method of the manufacturingmethod of forming chamber 440.

In some embodiments, the first process may be a thermoforming process.Thermoforming is a manufacturing process where a plastic sheet is heatedto a pliable forming temperature, formed to a specific shape in a mold,and trimmed to create a usable product. To complete the first processdescribed above with thermoforming one or both of first die 705 andsecond die 710 may be heated.

FIG. 9 shows a second process of a manufacturing method of forming thechamber shown in FIG. 6. As shown in FIG. 9, the second process may becompleted by a second die set 900. Second die set 900 may include athird die 905 and a fourth die 910. FIG. 9 also shows chamber 440 aftercompletion of the first process of the manufacturing method with secondchamber barrier layer fixedly attached to first tensile member layer 460and with bonded peripheral edge 925 formed by the welding of firstchamber barrier layer 445 with second chamber barrier layer 450. Also,after completion of the first process, chamber 440 may have an elongateindentation, which may form a flex groove 480.

FIG. 10 shows a further stage of the second process shown in FIG. 9.FIG. 10 shows third die 905 and fourth die 910 being advanced toward oneanother to compress the chamber. Accordingly, the second process mayinclude bonding first tensile member layer 460 to first chamber barrierlayer 445. In addition, the second process may include bonding secondtensile member layer 465 to second chamber barrier layer 450. Also, bycompressing substantially the entire chamber, the steps of bonding firsttensile member layer 460 to first chamber barrier layer 445 and bondingsecond tensile member layer 465 to second chamber barrier layer 450 areperformed simultaneously in second die set 900 as part of the secondprocess.

In some embodiments, third die 905 may include a die groove 920. Duringthe second process, the flex groove 915 may be aligned with die groove920. Accordingly, during the heating process, the bond that had alreadybeen formed between second chamber barrier layer 450 and first tensilemember layer 460 would not be reheated significantly.

In some embodiments, the second process may utilize radiofrequencywelding (RF welding) to perform the bonding steps of the second process.Radio frequency welding may also be referred to as “high frequencywelding.” Radio frequency welding uses electromagnetic energy andpressure to weld and permanently bond thermoplastic, vinyl and coatedfabrics to fixedly attach two components by forming a new, permanentbond. When cooled, the newly formed bond is as strong as or evenstronger than the original materials. By using radio frequency welding,the heating/welding can be targeted at particular portions of thestacked arrangement of chamber components without reheating welds thatwere formed in the first (thermoforming) process. For example, only theportions corresponding to the sections of second tensile member layer465, and not at flex groove 915.

FIG. 11 shows a further step of the method of forming the chamber shownin FIG. 6. As shown in FIG. 11, once the tensile member is bonded to thebarrier layers of the chamber, the chamber may be inflated with apressurized fluid. In some embodiments, the inflation may be performedwhile the chamber resides in the second die set.

As also shown in FIG. 11, in some embodiments, chamber 440 may beinflated with a pressurized fluid 940. In some embodiments, theinjection of pressurized fluid 940 may be performed while chamber 440 iscompressed within second die set 900. Upon pressurization, the top andbottom sides of chamber 440 may be extended up and down, respectively,increasing the height of the stacked arrangement of chamber components.This inflation of chamber 440 may extend tethers 470 and place tethers470 in tension, as shown in FIG. 11.

Once the chamber is fully assembled, the method may includeincorporating the chamber into the sole structure of the article offootwear. In addition, the method may include attaching the solestructure to the upper.

FIG. 12 shows an assembled, cross-sectional view of the chamber formedin the method shown in FIGS. 7-11. That is, FIG. 12 illustrates chamber440 after assembly using first die set 700 and second die set 900. Asshown in FIG. 12, first peripheral barrier layer portion 915 of firstchamber barrier layer 445 is joined to second peripheral barrier layerportion 920 of second chamber barrier layer 450. In some embodiments,the joinder of these portions of chamber 440 may form a flange, whichmay be trimmed after or during the sealing of first peripheral barrierlayer portion 915 to second peripheral barrier layer portion 920.

Tethers 470 may extend across the interior void within chamber 440 andare placed in tension by the outward force of the pressurized fluid uponfirst chamber barrier layer 445 and second chamber barrier layer 450,thereby preventing chamber 440 from expanding outward and retaining theintended shape of chamber 440. Whereas the peripheral bond of firstperipheral barrier layer portion 915 to second peripheral barrier layerportion 920 joins the polymer sheets to form a seal that prevents thefluid from escaping, tensile member 455 prevents chamber 440 fromexpanding outward or otherwise distending due to the pressure of thefluid. That is, tensile member 455 effectively limits the expansion ofchamber 440 to retain an intended shape of surfaces of first chamberbarrier layer 445 and second chamber barrier layer 450.

FIG. 12 illustrates chamber 440 right side up, with flex groove 480facing downward as it may be when incorporated in an article offootwear. In this orientation, as shown in FIG. 12, a portion of thebottom barrier layer (i.e., second barrier layer 450) extends upward inthe gap 725 between first tensile member layer section 502 and secondtensile member layer section 503. Further, the bottom barrier layer(i.e., second barrier layer 450) is joined to the lower surface 510 offirst tensile member layer 460.

In some embodiments, the chamber may be configured such that the chamberbarrier layer may be angled in the area where it extends betweensections of the tensile member. For example, in some embodiments, theportion of the lower chamber barrier layer that extends upward towardthe upper tensile member layer may extend from the lower tensile memberlayer to the upper tensile member layer at an angle that isnon-perpendicular with respect to the upper tensile member layer. Suchan angled configuration may provide stability and control of shearforces within the chamber.

FIG. 13 shows a chamber 1140 including a first chamber barrier layer1145 and a second chamber barrier layer 1150. Chamber 1140 may alsoinclude a tensile member 1155, which may include a first tensile memberlayer 1160 and a second tensile member layer 1165. A plurality oftethers 1170 may extend between first tensile member layer 1160 andsecond tensile member layer 1165. Second tensile member layer 1165 mayinclude separate sections, such as a first tensile member layer section1101 and a second tensile member layer section 1102. The characteristicsof these components may be the same or similar to correspondingcomponents of other embodiments discussed above.

As shown in FIG. 13, a portion 1105 of second chamber barrier layer 1150may extend toward and be fixedly attached to a lower surface 1110 offirst tensile member layer 1160, thus forming an elongate indentation1180 in chamber 1140. As further shown in FIG. 13, at least one area ofportion 1105 of second chamber barrier layer 1150 that extends towardfirst tensile member layer 1160 may extend from second tensile memberlayer 1165 to first tensile member layer 1160 at an angle 1115 that isnon-perpendicular with respect to first tensile member layer 1160. Thatis, at least one area of the portion of the bottom barrier layer thatextends upward in the gap between the first tensile member layer sectionand the second tensile member layer section extends from the secondtensile member layer to the first tensile member layer at an angle thatis non-perpendicular with respect to the first tensile member layer.Angle 1115 may be any suitable non-perpendicular angle. Smaller anglesmay provide the angled portion of second chamber barrier layer 1150 witha more horizontal configuration, thus providing greater amounts ofstability and horizontal support.

When assembling the chamber, the distance between the bonded areabetween the chamber barrier layer and the tensile member layer and theedge of the tensile member layer adjacent the gap may be taken intoconsideration when sizing the first die set. In particular, the ratiobetween the height of the projection that extends into the gap and theheight between the upper and lower dies of the first die set maydetermine how close to the edge of the second tensile member layer thebonded area between the second chamber barrier layer and the firsttensile member layer may be formed. This ratio may influence the angleof the chamber barrier layer in the gap between sections of the tensilemember layer.

Although FIG. 13 illustrates chamber 1140 fully assembled, For purposesof illustration, FIG. 13 shows a die 1195 in place for reference. Forsimplicity, the opposing die is not shown. Die 1195 includes aprojection 1180, which may be used to extend second barrier layer 1150into the gap and bond it to first tensile member layer 1160. During thatprocess, second chamber barrier layer 1150 may be drawn tightly againstdie 1195, as shown by dashed line 1186. Once the die is removed, andchamber 1140 is inflated, second chamber barrier layer 1150 may betightened and, therefore, move in a direction indicated by arrow 1188and arrow 1190 to form the angled configuration of second chamberbarrier layer 1150. The amount to which the barrier layer becomes angleddepends on the ratio of the height of projection 1180 and the heightbetween die 1195 and it's opposing die. The amount to which the barrierlayer becomes angled may also depend on the distance 1184 between edge1182 of second tensile member layer 1182 and the bonded area betweensecond chamber barrier layer 1150 and first tensile member layer 1160.It will be noted that the dimensions and proportions shown in thedrawings are schematic and not necessarily to scale.

In some embodiments where the gap between sections of the tensile membersections is smaller, the amount of the bottom chamber barrier layer thatis unlined with tensile member is minimized. This may increase thestructural integrity of the chamber, and simplify the construction ofthe assembly. For example, a smaller portion of the tensile member layermay be omitted/removed to create the gap between tensile membersections.

In order to narrow the distance between the bonded area between thesecond chamber barrier layer and the first tensile member layer and theedge of the second tensile member layer, more length of the secondtensile member layer may be gathered during the first process of themanufacturing method. In particular, elongate recesses may be located onopposing sides of the projection. The second chamber barrier layer maybe drawn into the elongate recesses, so that, when the chamber isassembled and inflated, there is more length of chamber barrier layer toform the walls of the flex groove.

FIG. 14 shows another die configured to perform a portion of a method offorming a chamber. For simplicity, FIG. 14 shows only a first die 1400and a first chamber barrier layer 1405. As shown in FIG. 14, die 1400may include one or more vacuum holes, through which air may be removedto create a vacuum pressure in order to draw first chamber barrier layer1405 against a surface 1445 of die 1400. For example, die 1400 mayinclude a first vacuum hole 1420, a second vacuum hole 1425, a thirdvacuum hole 1430, and a fourth vacuum hole 1435.

In some embodiments, surface 1445 may be a substantially planar diesurface. Die 1400 may include an elongate projection 1440 for extendingfirst chamber barrier layer 1405 into a gap between sections of atensile member layer. In some embodiments, elongate projection 1440 mayhave a substantially trapezoidal cross-sectional shape, as also shown inFIG. 14. Further, die 1400 may include a first elongate recess 1410adjacent elongate projection 1440. Die 1400 may also include a secondelongate recess 1415 adjacent elongate projection 1440 on an oppositeside of elongate projection 1440 from first elongate recess 1410.

FIG. 15 shows the die of FIG. 14 with a chamber barrier layer drawnagainst it using vacuum pressure. That is, the method may includedrawing first chamber barrier layer 1405 against die 1400 by creating areduced pressure using a vacuum, so that first chamber barrier layer1405 extends into first elongate recess 1410 and second elongate recess1415. This collects extra length of first chamber barrier layer 1405 ina first portion 1450 and a second portion 1460. First portion 1450provides additional length to the barrier layer that adds to the heightof the flex groove that will be formed. This additional length isrepresented by first dimension 1455. Similarly, second portion 1460provides additional length represented by second dimension 1465. As alsoshown in FIG. 15, the additional length drawn into first elongate recess1410 and second elongate recess 1415 pulls first chamber barrier layer1405 inward from its end points, as represented by a third dimension1470.

FIG. 16 shows an assembled and inflated chamber 1600 formed in themethod including the process that is partially shown in FIG. 15. Chamber1600 may include a second chamber barrier layer 1605. Also, chamber 1600may include a tensile member 1607, which may include a first tensilemember layer 1610 and a second tensile member layer 1615. Tensile member1607 may include a plurality of tethers 1620. Extra height added tofirst chamber barrier layer 1405 by first elongate recess 1410 andsecond elongate recess 1415 is illustrated in FIG. 16 by first portion1450 of first chamber barrier layer 1405. As shown in FIG. 16, firstportion 1450 may have a first height 1475. In addition, second portion1460 may have a second height 1485.

The added length provided to the chamber barrier layer in the flexgroove may enable the edge of the tensile member to be closer to thebond between the barrier layer and the tensile member layer in the flexgroove. In addition, if the height proportions between the elongateprojection and the height of the first die set are selected accordingly,the chamber may be assembled using a single bonding process instead oftwo separate bonding processes. For example, in one step, in one dieset, the first chamber barrier layer may be bonded to the second tensilemember layer, the peripheral edges of the chamber barrier layers may bewelded, and the tensile member layers may be bonded to the first chamberbarrier layer and the second chamber barrier layer.

FIG. 17 shows an assembled, cross-sectional view of another exemplaryfluid-filled chamber. In particular, FIG. 17 shows a chamber 1240including a first chamber barrier layer 1245 and a second chamberbarrier layer 1250. Chamber 1240 may also include a tensile member 1255,which may include a first tensile member layer 1260 and a second tensilemember layer 1265. A plurality of tethers 1270 may extend between firsttensile member layer 1260 and second tensile member layer 1265. Secondtensile member layer 1265 may include separate sections, such as a firsttensile member layer section 1201 and a second tensile member layersection 1202. The characteristics of these components may be the same orsimilar to corresponding components of other embodiments discussedabove.

As shown in FIG. 17, a portion 1205 of second chamber barrier layer 1250may extend toward and be fixedly attached to a lower surface 1210 offirst tensile member layer 1260, thus forming an elongate indentation1280 in chamber 1240. As further shown in FIG. 17, at least one area ofportion 1205 of second chamber barrier layer 1250 that extends towardfirst tensile member layer 1260 may extend from second tensile memberlayer 1265 to first tensile member layer 1260 at an angle 1281 that isnon-perpendicular with respect to first tensile member layer 1260. Inaddition, as also shown in FIG. 17, a first portion 1203 of secondtensile member layer 1265 may be fixedly attached to the area portion1205 of second chamber barrier layer 1250 that extends atnon-perpendicular angle 1281. A second portion 1204 of second tensilemember layer 1265 may be arranged similarly to first portion 1203. Asshown in FIG. 17, in some embodiments, some of tethers 1270 that areattached to first portion 1203 and second portion 1204 may be less thanfully extended when chamber 1240 is inflated.

It will also be noted that, although exemplary chambers disclosed hereinare shown with the elongate indentations on a lower side, in someembodiments, the indentations may be provided on the upper side.Accordingly, in some embodiments, the upper barrier layer may extenddownward toward, and join with, the lower tensile member layer. That is,the chambers may be configured with an arrangement that is essentiallyupside down from that shown in the accompanying figures. In suchembodiments, with indentations on the upper side of the chamber, theindentations may enable articulation between sections of the chamber,while the thinner portions of the chamber (at the barrier layer/tensilemember layer junction) act as living hinges. In some embodiments, thebonding of a portion of chamber barrier layer to an opposing portion oftensile member layer in a gap between sections of the tensile member mayform opposing indentations or flex grooves in the chamber. For example,opposing flex grooves may extend into the top and bottom surfaces of thechamber.

In some configurations, the chamber may be formed without the elongateindentation where the lower chamber barrier layer extends upward to jointo the upper tensile member layer. Such configurations may be used, forexample, in footwear embodiments that do not include flex grooves insole structure components. For instance, the midsole may include acontinuous recess that is not broken up by elongate ribs correspondingwith flex groove portions.

FIGS. 13 and 14 show a chamber 1340 including a first chamber barrierlayer 1345 and a second chamber barrier layer 1350. Chamber 1340 mayalso include a tensile member 1355, which may include a first tensilemember layer 1360 and a second tensile member layer 1365. A plurality oftethers 1370 may extend between first tensile member layer 1360 andsecond tensile member layer 1365. Second tensile member layer 1365 mayinclude separate sections, such as a first tensile member layer section1301 and a second tensile member layer section 1302. The characteristicsof these components may be the same or similar to correspondingcomponents of other embodiments discussed above.

As shown in FIG. 13, a portion 1305 of second chamber barrier layer 1350may extend toward and be fixedly attached to a lower surface 1310 offirst tensile member layer 1360. As further shown in FIG. 13, a portion1326 of second chamber barrier layer 1350 may be substantially foldedupon itself, thus substantially eliminating the space between chambersections. This configuration enables the gap 1325 between first tensilemember layer section 1301 and second tensile member layer section 1302to be minimized.

As shown in FIG. 14, when chamber 1340 is articulated, the sections ofchamber 1340 may hingedly rotate about the junction between portion 1305of second chamber barrier layer 1350 and lower surface 1310 of firsttensile member layer 1360. This hinge-like articulation may separatesections of chamber 1340, thereby forming an opening 1380. Thisconfiguration may be formed with a very narrow projection in the die,and with relatively deep elongate recesses on opposing sides of theprojection.

It will be noted that the disclosed chamber configurations and tensilemember arrangements may be implemented in articles other than footwear.For example, such chambers may be used for other articles such asgarments and sporting equipment. In some cases, such chambers may beused to provide padding for sports garments, and the disclosed elongateindentations may provide flexibility that enables the padding to conformto the curvatures of various parts of the body. In other cases, suchchambers may be used to provide padding in sports equipment, such asbaseball gloves, catchers padding, lacrosse and football pads, and othersuch equipment. The flexibility of such chambers may enable suchequipment to not only conform with the curvature of various parts of thebody, but also to enable articulation of adjoined components of theequipment.

While various embodiments of the invention have been described, thedescription is intended to be exemplary, rather than limiting, and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the invention. Although many possible combinations of features areshown in the accompanying figures and discussed in this detaileddescription, many other combinations of the disclosed features arepossible. Therefore, it will be understood that any of the featuresshown and/or discussed in the present disclosure may be implementedtogether in any suitable combination and that features of one embodimentmay be implemented in other disclosed embodiments. Accordingly, theinvention is not to be restricted except in light of the attached claimsand their equivalents. Also, various modifications and changes may bemade within the scope of the attached claims.

What is claimed is:
 1. A method of making an article of footwear havingan upper and a sole structure secured to the upper, the methodcomprising: forming a chamber for receiving a pressurized fluid by:assembling a stacked arrangement of chamber components including: afirst chamber barrier layer; a second chamber barrier layer; and atensile member extending between the first chamber barrier layer and thesecond chamber barrier layer, the tensile member including a firsttensile member layer, a second tensile member layer, and a plurality oftethers connecting the first tensile member layer to the second tensilemember layer, wherein the second tensile member layer includes a firstsection and a second section separate from the first section; bondingthe first chamber barrier layer to the second chamber barrier layer toform peripheral portions of the chamber and to define an interior voidbetween the first chamber barrier layer and the second chamber barrierlayer; and extending a portion of the second chamber barrier layertoward the first tensile member layer between the first section of thesecond tensile member layer and the second section of the second tensilemember layer, pressing the portion of the second chamber barrier layeragainst the first tensile member layer; and joining the portion of thesecond chamber barrier layer to the first tensile member layer betweenthe first section of the second tensile member layer and the secondsection of the second tensile member layer; bonding the first tensilemember layer to the first chamber barrier layer; bonding the secondtensile member layer to the second chamber barrier layer; inflating thechamber with a pressurized fluid; incorporating the chamber into thesole structure; and attaching the sole structure to the upper.
 2. Themethod of claim 1, wherein the steps of bonding the first chamberbarrier layer to the second chamber barrier layer to form peripheralportions of the chamber and joining a portion of the second chamberbarrier layer to the first tensile member layer are performedsimultaneously in a first die set as part of a first process.
 3. Themethod of claim 2, wherein the first die set includes a first dieincluding a first peripheral die projection and a second die including asecond peripheral die projection, configured to mate with the firstperipheral die projection; and wherein bonding the first chamber barrierlayer to the second chamber barrier layer to form peripheral portions ofthe chamber includes: placing a portion of the first chamber barrierlayer and a portion of the second chamber barrier layer between thefirst peripheral die projection and the second peripheral dieprojection; and applying pressure to the first chamber barrier layer andthe second chamber barrier layer between the first peripheral dieprojection and the second peripheral die projection.
 4. The method ofclaim 3, wherein the second die includes a projection; and whereinjoining a portion of the second chamber barrier layer to the firsttensile member layer involves extending a portion of the second chamberbarrier layer toward the first tensile member layer using the projectionby advancing the first die and the second die toward one another toextend the projection between the first section of the second tensilemember layer and the second section of the second tensile member layerand press the portion of the second chamber barrier layer toward andagainst the first tensile member layer.
 5. The method of claim 4,wherein the second die includes a first recessed portion adjacent theprojection, the method further including: drawing the second chamberbarrier layer against the second die by creating a reduced pressureusing a vacuum, so that the second chamber barrier layer extends intothe first recessed portion adjacent the projection.
 6. The method ofclaim 5, wherein the second die includes a second recessed portionadjacent the projection and located on an opposite side of theprojection from the first recessed portion, and wherein drawing thesecond chamber barrier layer against the second die extends the secondchamber barrier layer into the second recessed portion of the seconddie.
 7. The method of claim 4, wherein the projection is an elongateprojection; and wherein the step of joining the portion of the secondchamber barrier layer to the first tensile member layer by extending theportion of the second chamber barrier layer toward the first tensilemember layer using the elongate projection forms an elongate flex groovein the chamber.
 8. The method of claim 2, wherein the steps of bondingthe first tensile member layer to the first chamber barrier layer andbonding the second tensile member layer to the second chamber barrierlayer are performed simultaneously in a second die set as part of asecond process.
 9. The method of claim 8, wherein the first process is athermoforming process; and wherein the second process utilizesradiofrequency welding to perform the bonding steps of the secondprocess.
 10. The method of claim 1, wherein the second tensile memberlayer is discontinuous such that the first tensile member layer sectionis separated from the second tensile member layer section by a gap. 11.The method of claim 1, wherein the portion of the second chamber barrierlayer is joined to a first side of the first tensile member layer andthe first chamber barrier layer is bonded to a second side of the firsttensile member layer.
 12. A method of making a sole structure for anarticle of footwear, including forming a chamber for receiving apressurized fluid, comprising: assembling a stacked arrangement ofchamber components including: a first chamber barrier layer; a secondchamber barrier layer; and a tensile member extending between the firstchamber barrier layer and the second chamber barrier layer, the tensilemember including a first tensile member layer, a second tensile memberlayer, and a plurality of tethers connecting the first tensile memberlayer to the second tensile member layer, wherein the second tensilemember layer is discontinuous such that a first section of the secondtensile member layer is separated from a second section of the secondtensile member layer by a gap; bonding the first chamber barrier layerto the second chamber barrier layer to form peripheral portions of thechamber and to define an interior void between the first chamber barrierlayer and the second chamber barrier layer; and extending a portion ofthe second chamber barrier layer toward the first tensile member layerin the gap between the first section of the second tensile member layerand the second section of the second tensile member layer, pressing theportion of the second chamber barrier layer against the first tensilemember layer; and joining the portion of the second chamber barrierlayer to the first tensile member layer between the first section of thesecond tensile member layer and the second section of the second tensilemember layer; bonding the first tensile member layer to the firstchamber barrier layer; bonding the second tensile member layer to thesecond chamber barrier layer; and inflating the chamber with apressurized fluid.
 13. The method of claim 12, wherein the steps ofbonding the first chamber barrier layer to the second chamber barrierlayer to form peripheral portions of the chamber and joining a portionof the second chamber barrier layer to the first tensile member layerare performed simultaneously in a first die set as part of a firstprocess.
 14. The method of claim 13, wherein the first die set includesa first die and a second die; wherein the second die includes aprojection; and wherein joining a portion of the second chamber barrierlayer to the first tensile member layer involves extending a portion ofthe second chamber barrier layer toward the first tensile member layerusing the projection by advancing the first die and the second dietoward one another to extend the projection into the gap between thefirst section of the second tensile member layer and the second sectionof the second tensile member layer and press the portion of the secondchamber barrier layer toward and against the first tensile member layer.15. The method of claim 14, wherein the projection is an elongateprojection; and wherein the step of joining the portion of the secondchamber barrier layer to the first tensile member layer by extending theportion of the second chamber barrier layer toward the first tensilemember layer using the elongate projection forms an elongate flex groovein the chamber.
 16. The method of claim 13, wherein the steps of bondingthe first tensile member layer to the first chamber barrier layer andbonding the second tensile member layer to the second chamber barrierlayer are performed simultaneously in a second die set as part of asecond process.
 17. The method of claim 16, wherein the first process isa thermoforming process; and wherein the second process utilizesradiofrequency welding to perform the bonding steps of the secondprocess.
 18. The method of claim 12, wherein the portion of the secondchamber barrier layer is joined to a first side of the first tensilemember layer and the first chamber barrier layer is bonded to a secondside of the first tensile member layer.
 19. A method of making a solestructure for an article of footwear, including forming a chamber forreceiving a pressurized fluid, comprising: assembling a stackedarrangement of chamber components including: a first chamber barrierlayer; a second chamber barrier layer; and a tensile member extendingbetween the first chamber barrier layer and the second chamber barrierlayer, the tensile member including a first tensile member layer, asecond tensile member layer, and a plurality of tethers connecting thefirst tensile member layer to the second tensile member layer, whereinthe second tensile member layer is discontinuous such that a firstsection of the second tensile member layer is separated from a secondsection of the second tensile member layer by a gap; bonding the firstchamber barrier layer to the second chamber barrier layer to formperipheral portions of the chamber and to define an interior voidbetween the first chamber barrier layer and the second chamber barrierlayer; and extending a portion of the second chamber barrier layertoward the first tensile member layer in the gap between the firstsection of the second tensile member layer and the second section of thesecond tensile member layer, pressing the portion of the second chamberbarrier layer against the first tensile member layer; and joining theportion of the second chamber barrier layer to the first tensile memberlayer; and inflating the chamber with a pressurized fluid.
 20. Themethod of claim 19, wherein the projection is an elongate projection;and wherein the step of joining the portion of the second chamberbarrier layer to the first tensile member layer by extending the portionof the second chamber barrier layer toward the first tensile memberlayer using the elongate projection forms an elongate flex groove in thechamber.
 21. The method of claim 20, wherein the first process is athermoforming process.
 22. The method of claim 21, further including asecond process involving bonding the first chamber barrier layer to thefirst tensile member layer and bonding the second chamber barrier layerto the second tensile member layer; wherein the bonding steps of thesecond process are performed by radiofrequency welding.
 23. The methodof claim 19, wherein the portion of the second chamber barrier layer isjoined to a first side of the first tensile member layer and the firstchamber barrier layer is bonded to a second side of the first tensilemember layer.